Brake assembly with sensor unit

Abstract

A brake assembly is disclosed that includes a brake pad assembly, a pad spring, and a sensor unit. The brake pad assembly includes a friction material disposed on a backplate. The pad spring is mounted to the backplate. The sensor unit rides across the backplate and extends from the backplate to the pad spring.

Description

TECHNICAL FIELD

[0001] This document relates to a brake assembly having at least one sensor unit mounted to a backplate of a brake pad assembly. BACKGROUND

[0002] A disc brake assembly having a sensor assembly is disclosed in U.S. Patent Application No. 17 / 345,179.

[0003] SUMMARY

[0004] In at least one embodiment, a brake assembly is provided. The brake assembly includes a brake pad assembly, a pad spring, and a sensor unit. The brake pad assembly includes a friction material disposed on a front side of a backplate. The pad spring is mounted to the backplate. The sensor unit rides across the backplate and extends from the backplate to the pad spring. BRIEF DESCRIPTION OF DRAWINGS

[0005] Figure 1 is a perspective view of an example of a brake assembly.

[0006] Figure 2 is an enlarged perspective view of some components of the brake assembly shown in Figure 1

[0007] Figure 3 is an exploded view of Figure 2

[0008] Figure 4 is a cross-sectional view along section line 4-4, with internal features of the sensor unit omitted for clarity.

[0009] Figure 5 is a perspective view of an example of a sensor unit and a sleeve.

[0010] Figure 6 is a cross-sectional view along section line 6-6.

[0011] Figure 7 is a fragmentary perspective view of another configuration of a sensor unit.

[0012] Figure 8 is a perspective view of a configuration of a sensor unit having external electrical conductors.

[0013] Figure 9 is a top view of the brake assembly of Figure 1

[0014] Figure 10 is a perspective view of the brake assembly of Figure 9 ​​​a perspective view of a sensor unit.

[0015] Figure 11 is based on Figure 6 a cross-sectional view showing a sensor unit movable relative to a connecting member. DETAILED DESCRIPTION

[0016] Detailed embodiments of the application are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the application which can be embodied in various forms and alternative forms. The accompanying drawings are not necessarily to scale; some features can be exaggerated or minimized for the sake of clarity. The specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the application.

[0017] Referring to Figure 1 , an example of a brake assembly 10 is shown. The brake assembly 10 can be provided as part of a vehicle, such as a truck, bus, farm equipment, military transport or military vehicle, or cargo loading equipment for land, air, or marine vessels. In at least one configuration, the brake assembly 10 can be configured as a disc brake assembly, and can include a brake carrier 20, a brake caliper 22, at least one brake pad assembly 24, a retainer band 26, one or more pad springs 28, and one or more sensor units 30. Optionally, the brake assembly 10 can also provide one or more brake pad retraction springs 32, an example of which is best shown in Figure 9 .

[0018] Referring to Figure 1 , the brake carrier 20 can facilitate installation of the brake assembly 10. For example, the brake carrier 20 can be fixedly mounted to a component of the vehicle, such as an axle assembly or a knuckle. The brake carrier 20 can receive and support the brake pad assembly 24, and can include an opening through which a brake rotor 40 (shown in dashed lines in Figure 4 and Figure 9 may extend. For example, the brake carrier 20 can cradle or support the bottom and lateral sides of the brake pad assembly 24. In at least one configuration, the brake carrier 20 can straddle the brake rotor 40, and can help to position the brake pad assembly 24 on opposite sides of the brake rotor 40.

[0019] The brake caliper 22 can be mounted to the brake carrier 20 and can support various components of the brake assembly 10. Additionally, the brake caliper 22 can facilitate positioning of the brake pad assembly 24 relative to the brake rotor 40 to promote braking of the vehicle, as will be discussed in greater detail below. In at least one configuration, the brake caliper 22 can include a caliper housing 50 and a caliper bridge 52.

[0020] The caliper housing 50 can be movably disposed on the brake carrier 20. For example, the caliper housing 50 can be slidable along a pair of guide pins that can be fixedly disposed on the brake carrier 20. The caliper housing 50 can receive or support various components that can facilitate actuation of the brake pad assembly 24. For example, the caliper housing 50 can support a tappet 60 that can protrude from an interior cavity of the caliper housing 50.

[0021] The tappet 60 can extend from the caliper housing 50 toward the brake rotor 40 to engage the brake pad assembly 24. The tappet 60 can be movable relative to the caliper housing 50 along an axis such that the tappet 60 can move toward and away from the brake rotor 40. For example, an actuator can extend the tappet 60 to actuate the brake pad assembly 24 disposed between the caliper housing 50 and the brake rotor 40 into engagement with the brake rotor 40. Then, a reaction force can move the caliper housing 50 and the caliper bridge 52 relative to the brake carrier 20 to actuate the brake pad assembly 24 disposed between the caliper bridge 52 and the brake rotor 40 into engagement with an opposite side of the brake rotor 40 to facilitate slowing rotation of the brake rotor 40 and the associated vehicle wheel.

[0022] The caliper bridge 52 can be fixedly positioned relative to the caliper housing 50. The caliper bridge 52 can be integrally formed with the caliper housing 50 or can be a separate component that is mounted to the caliper housing 50. For example, the caliper bridge 52 can be coupled or secured to the caliper housing 50 with one or more fasteners, such as bolts. In at least one configuration, the caliper bridge 52 can cooperate with the caliper housing 50 to define a cavity 70.

[0023] The cavity 70 can at least partially receive the brake pad assembly 24 and the brake rotor 40. The cavity 70 can be configured as a large through-hole that can be encircled by the brake caliper 22. A portion of the brake carrier 20 can extend into the cavity 70 and can facilitate positioning of the brake pad assembly 24. The brake pad assembly 24 can be inserted into the cavity 70 and mounted on the brake carrier 20 or removed from the cavity 70 and the brake carrier 20 when the retainer band 26 is removed.

[0024] Referring primarily to Figure 2 to Figure 4A pair of brake pad assemblies 24 can be received in the brake carrier 20. The brake pad assemblies 24 can be disposed on opposite sides of the brake rotor 40 and can have similar or identical configurations. For ease of reference, the brake pad assembly 24 disposed between the brake rotor 40 and the tappet 60 can be referred to as an inboard brake pad assembly, while the brake pad assembly 24 disposed between the brake rotor 40 and the caliper bridge 52 can be referred to as an outboard brake pad assembly. Also for ease of reference, the brake pad assemblies 24 can be referred to hereinafter as "first brake pad assemblies" and "second brake pad assemblies." The first and second brake pad assemblies can be the inboard and outboard brake pad assemblies, respectively, or vice versa. In at least one configuration, the brake pad assemblies 24 can include a backplate 80 and a friction material 82.

[0025] The backplate 80 can be a structural member of the brake pad assembly 24. The backplate 80 can be configured as a generally flat plate and can be made of any suitable material, such as a metal alloy. The tappet 60 can engage the backplate 80 of the inboard brake pad assembly 24. For example, the tappet 60 can engage a rear side 90 of the backplate 80 of the inboard brake pad assembly 24, which faces away from the brake rotor 40 and can be disposed opposite a front side 92 of the backplate 80 and the friction material 82. The rear side 90 of the backplate 80 of the outboard brake pad assembly 24 can engage the caliper bridge 52. The backplate 80 can include a plurality of tabs or hooks that can facilitate installation of the pad spring 28. These tabs or hooks can protrude or extend from a top side of the backplate 80 and can extend away from an opposite bottom side of the backplate 80, which can engage the brake carrier 20.

[0026] Referring to Figure 2 and Figure 3 The backplate 80 can optionally have one or more holes 94 that can facilitate installation of the brake pad retraction spring 32. In at least one configuration, the holes 94 can be disposed above the friction material 82.

[0027] The friction material 82 can be disposed on the front side 92 of the backplate 80 and can face the brake rotor 40. During vehicle braking, the friction material 82 can contact the brake rotor 40. The friction material 82 can define at least one recess 84. The recess 84 can extend from a top side of the friction material 82 that faces away from the pad spring 28. The recess 84 can extend through a thickness of the friction material 82. In at least one configuration, the recess 84 can taper along the thickness of the friction material 82 (e.g., the recess 84 can taper so as to narrow as the recess 84 extends toward the backplate 80), vertically or radially (e.g., the recess 84 can taper so as to narrow as the recess 84 extends downward or away from the pad spring 28), or a combination thereof.

[0028] Referring toFigure 1 The retainer band 26 can be removably mountable to the brake caliper 22. For example, the retainer band 26 can be removed from the brake caliper 22 to facilitate removal or replacement of the brake pad assembly 24, and can be mounted on the brake caliper 22 to inhibit removal of the brake pad assembly 24. The retainer band 26 can extend across the brake pad assembly 24 and the cavity 70 of the brake caliper 22 to help retain the brake pad assembly 24 in the brake carrier 20 when the retainer band 26 is secured to the brake caliper 22. The retainer band 26 can engage or contact the pad springs 28 when the retainer band 26 is mounted and secured to the brake caliper 22. A first end of the retainer band 26 can be mounted to the caliper housing 50. A second end of the retainer band 26 disposed opposite the first end can be disposed on and can be secured to the caliper bridge 52, such as with fasteners like bolts.

[0029] The pad springs 28 can exert a biasing force on components received in the cavity 70, such as the brake pad assembly 24 or the tappet 60. For example, the pad springs 28 can be mounted to the backplate 80 of the brake pad assembly 24, the tappet 60, or a combination thereof. In the illustrated configuration, three pad springs 28 are shown; however, it is contemplated that a lesser number of pad springs 28 can be provided. The pad springs 28 can be spaced apart from one another and can extend from or into the retainer band 26 toward the cavity 70. For example, viewed from the angle shown in Figure 1 The uppermost pad spring 28 can extend from the retainer band 26 to the tappet 60, the middle pad spring 28 can extend from the retainer band 26 to the first brake pad assembly 24, and the remaining pad spring 28 can extend from the retainer band 26 to the second brake pad assembly 24, viewed from the angle shown in Figure 2 As best shown in

[0030] Referring to Figure 1 and Figure 2bracket 20 and the bottom side of the backplate 80. The sensor unit 30 can be partially received in the recess 84 of the friction material 82, which can allow the sensor unit 30 to engage the friction material 82 to limit circumferential movement of the sensor unit 30 relative to the friction material 82. In at least one configuration and as best shown in FIG. 1, the sensor unit 30 can include a front body 100, a rear body 102, a bridge 104, and one or more sensors, such as a first sensor 106 and a second sensor 108. The sensor unit 30 can also include or be associated with one or more electrical conductors 110, a sleeve 112, and a coil member 114. Figure 5 and Figure 6 The sensor unit 30 can include a front body 100, a rear body 102, a bridge 104, and one or more sensors, such as a first sensor 106 and a second sensor 108. The sensor unit 30 can also include or be associated with one or more electrical conductors 110, a sleeve 112, and a coil member 114.

[0031] Referring to Figure 4 and Figure 5 The front body 100 can engage the front side 92 of the backplate 80. For example, the front body 100 can contact a portion of the front side 92 of the backplate 80 that is free of the friction material 82 and extend along that portion and into the recess 84 of the friction material 82. At least a portion of the front body 100 can have a width that is less than a width of the recess 84 to facilitate insertion of the front body 100 into the recess 84. Alternatively, the front body 100 can contact and conform to the shape of the recess 84. Further, a taper of the recess 84 can facilitate installation of the front body 100 while permitting the front body 100 to contact the plurality of sides or surfaces of the friction material 82 that define the recess 84 to help secure the front body 100. The front body 100 can protrude from the front side 92 toward the brake rotor 40 and the friction material 82. In at least one configuration, the front body 100 can have a thickness in a direction away from the rear body 102 that can be less than or equal to a thickness of the friction material 82 when the friction material 82 is un-worn. Optionally, the front body 100 can have a greater thickness than the rear body 102. As best shown in Figure 4 The front body 100 can extend further downward or further away from the pad spring than the rear body 102. In at least one configuration, the front body 100 can include a front body protrusion 120.

[0032] The front body protrusion 120 can be disposed proximate to the pad spring 28. The front body protrusion 120 can extend away from the friction material 82 or in an upward direction from the depicted perspective. In at least one configuration, the front body protrusion 120 can be aligned with and can extend from a front-facing side 122 of the front body 100 that faces away from the rear body 102. The front body protrusion 120 can be disposed adjacent to a side of the pad spring 28 that faces the brake rotor 40 and can assist in positioning the sensor unit 30 relative to the pad spring 28. Optionally, a side of the front body protrusion 120 that faces the pad spring 28 can engage the pad spring 28.

[0033] The rear body 102 can be spaced apart from the front body 100. The rear body 102 can engage the rear side 90 of the backing plate 80. For example, the rear body 102 can contact and extend along a portion of the rear side 90 of the backing plate 80. The rear body 102 can protrude from the rear side 90 of the backing plate 80 that faces away from the brake rotor 40 and the friction material 82. The rear body 102 can have the same width as the front body 100 or a different width. Additionally, the rear body 102 can be thicker than depicted, which can provide a greater volume for receiving circuitry or other components. In at least one configuration, the rear body 102 can have a rear body protrusion 130.

[0034] The rear body protrusion 130 can be spaced apart from the front body protrusion 120. The rear body protrusion 130 can be disposed proximate to the pad spring 28. The rear body protrusion 130 can extend in an upward direction from the depicted perspective. In at least one configuration, the rear body protrusion 130 can be aligned with and can extend from a rear-facing side 132 of the rear body 102 that faces away from the front body 100. The rear body protrusion 130 can be disposed adjacent to a side of the pad spring 28 that faces away from the brake rotor 40 and can assist in positioning the sensor unit 30 relative to the pad spring 28. In this way, the pad spring 28 can be received between the front body protrusion 120 and the rear body protrusion 130. Optionally, a side of the rear body protrusion 130 that faces the pad spring 28 can engage the pad spring 28.

[0035] The bridge 104 can interconnect the front body 100 and the rear body 102. For example, the bridge 104 can extend from the front body 100 to the rear body 102 and can extend across the backplate 80. The bridge 104 can engage the pad spring 28 and the backplate 80. For example, a top side 140 of the bridge 104 can face and can engage the pad spring 28, while a bottom side 142 of the bridge 104 can face and can engage a side of the backplate 80 that can face the retainer band 26, such as a top side of the backplate 80. The top side 140 can be longer than the bottom side 142. For example, the top side 140 can have a length from the front body protrusion 120 to the rear body protrusion 130 that is greater than a length of the bottom side 142 from the front body 100 to the rear body 102. A height of the bridge 104 from the top side 140 to the bottom side 142 can be less than a height of the front body 100 and the rear body 102.

[0036] The bridge 104 can be integrally formed with the front body 100 and the rear body 102. For example, the front body 100, the rear body 102, and the bridge 104 can be integrally formed from a polymeric material, such as silicone, that can withstand temperatures associated with braking while maintaining sufficient structural integrity (e.g., not melting). Further, such a material can limit heat absorption and can help provide a degree of thermal insulation, which can help protect the sensors inside the sensor unit 30.

[0037] Reference Figure 6 The sensors that the sensor unit 30 can provide will now be discussed. As an overview, one or more sensors can be encapsulated in the sensor unit 30. The sensors can be configured to provide signals indicative of one or more properties associated with the brake assembly 10. As an example, the sensors can detect or provide signals indicative of wear of the friction material 82, temperature of the brake pad assembly 24, and so forth. The sensors will be discussed below with reference to first and second sensors 106, 108 of different types or having different configurations; however, it is contemplated that a greater or lesser number of sensors can be provided.

[0038] The first sensor 106 can be encapsulated in the front body 100 of the sensor unit 30. For example, the first sensor 106 can be positioned between the front side 122 and the opposing back side 144 that faces the front side 92 of the backing plate 80 when the front body 100 is not worn. The first sensor 106 can provide a signal indicative of wear of the friction material 82. For example, the friction material 82 can contact the brake rotor 40 during braking, which can cause the friction material 82 to wear and decrease in thickness. After sufficient wear occurs, the side of the friction material 82 facing the brake rotor 40 can be approximately aligned with the front side 122 of the front body 100. As a result, additional brake application can cause engagement of the friction material 82 and the front body 100 with the brake rotor 40 and wear of the friction material 82 and the front body 100.

[0039] After sufficient wear occurs, the first sensor 106 or a portion thereof can be exposed and can contact the brake rotor 40 during braking and provide a signal that can be indicative of wear of the friction material 82 and that the brake pad assembly 24 should be replaced. For example, the signal can be generated by the first sensor 106 or can be associated with opening or closing an electrical circuit. For example, engagement of the brake rotor 40 with the first sensor 106 can break or otherwise disconnect an electrical circuit that is normally continuous, resulting in a change in one or more electrical properties, such as current or voltage, which can be detected or recognized by an electronic controller that can receive the signal in a manner known to those skilled in the art. In Figure 6 In the embodiment, the first sensor 106 is shown as having a first sensor portion 150 and a second sensor portion 152. The first sensor portion 150 is disposed closer to the front side 122 than the second sensor portion 152. Sufficient wear of the front body 100 can cause wear of the first sensor portion 150 and an open circuit associated with the first sensor portion 150, while operation of the second sensor portion 152 can not be affected. Thus, the signal can be indicative of wear of the friction material to at least the first sensor portion 150. Sufficient additional wear of the front body 100 can cause wear of the second sensor portion 152 and an open circuit associated with the second sensor portion 152. Thus, the signal can be indicative of wear of the friction material to at least the second sensor portion 152. It is contemplated that a greater or lesser number of sensor portions are provided. It is also contemplated that the first sensor portion 150 and the second sensor portion 152 can represent different sensors, rather than portions of the same sensor.

[0040] The second sensor 108 can also be packaged in the sensor unit 30. In at least one configuration, the second sensor 108 or portions thereof can be positioned further from the face side 122 than the first sensor 106. For example, the second sensor 108 or portions thereof can be positioned rearward of the first sensor 106, rearward of the front body 100, or both. For example, the second sensor 108 can be positioned or packaged in the bridge 104, the rear body 102, the sleeve 112, or combinations thereof. Some examples of these locations are represented by the circles shown in dashed lines in Figure 6 In at least one configuration, the second sensor 108 can provide a signal indicative of a temperature of the brake pad assembly 24. In such a configuration, the second sensor 108 can be any suitable type, such as a thermocouple, a thermistor, a semiconductor temperature sensor, or the like. Positioning the second sensor 108 further away from the friction material 82 can help limit the amount of heat conducted to the second sensor 108, and can allow for the use of a less expensive temperature sensor with a more limited operating range.

[0041] One or more electrical conductors 110 can be electrically connected to one or more sensors provided by the sensor unit 30. The electrical conductors 110 can be any suitable type, such as wires, ribbons, or the like. The electrical conductors 110 can be provided with an insulator or coating that can help withstand operating temperatures. For example, the electrical conductors 110 can be painted, which can also help reduce the amount of sheathing or insulating material provided around the electrical conductors 110. One or more electrical conductors 110 can be associated with the first sensor 106 and the second sensor 108. In Figure 6 The electrical conductors 110 are represented by solid lines in

[0042] The sleeve 112 can extend from the sensor unit 30. Additionally, the sleeve 112 can encircle one or more electrical conductors 110 and can package a portion of the electrical conductors 110 and the insulator or coating provided by the electrical conductors 110 that are disposed inside the sleeve 112. The sleeve 112 can be integrally formed with the sensor unit 30. For example, the sleeve 112 can be molded or formed from the same material as the front body 100, the rear body 102, the bridge 104, or combinations thereof. The sleeve 112 can extend from any suitable location on the sensor unit 30. In Figure 5 and Figure 6 In the configuration shown in

[0043] The sleeve 112 can include a plurality of protrusions 160 that can extend away from the electrical conductor 110. The protrusions 160 can help limit or reduce the surface area of the sleeve 112 that can contact other components and thus help reduce heat conduction into the sleeve 112, can increase the surface area available for cooling, or a combination thereof. The protrusions 160 can also help provide wear resistance to help protect the sensors and electrical conductors 110 inside the sensor unit 30. In some cases, the protrusions 160 can help improve the retention of the sleeve 112 in a desired position, such as when the protrusions 160 are compressed and secured inside a recess in another component of the brake assembly 10, such as the brake caliper 22, retainer band 26, or the like. In at least one configuration, the protrusions 160 can be spaced apart from one another and can encircle the electrical conductor 110. For example, the protrusions 160 can be configured as generally circular disks that are axially spaced apart from one another when the sleeve 112 is not bent or generally straight.

[0044] The coil member 114 can be received inside the sensor unit 30 and the sleeve 112. The coil member 114 can be similar to an elongated coil spring and include a plurality of coils that can extend around or spiral around the electrical conductor 110. At least a portion of the coil member 114 can be encapsulated in the sleeve 112 and can be encircled by one or more protrusions 160, if provided. Additionally, a portion of the coil member 114 can be encapsulated in a portion of the sensor unit 30. In the illustrated configuration, a first end of the coil member 114 is disposed in the rear body 102; however, it is contemplated that the coil member 114 can have a greater length and can extend into and be encapsulated in the bridge 104, the front body 100, or a combination thereof. A second end of the coil member 114 disposed opposite the first end can be located inside the sleeve 112 or can extend out of the sleeve 112. The coil member 114 can provide a variety of functions. For example, the coil member 114 can help reinforce or strengthen the connection between the sleeve 112 or the sleeve and the rear body 102 to help prevent the sleeve 112 from tearing. The coil member 114 can also be bent to a desired angle, shape, or orientation to help route the electrical conductor 110 and the sleeve 112 in a desired manner. For example, the coil member 114 can be bent or curved in a manner that helps route the electrical conductor 110 away from locations where crushing or damage can occur, such as away from one or more sides of movable components such as the brake pad assembly 24 or the tappet 60, and can then help maintain a desired shape, angle, or orientation. The coil member 114 can also provide strain relief, which can inhibit inadvertent disconnection of the electrical conductor 110 and can help dampen or inhibit vibrations from damaging the sensors or electrical connections.

[0045] As previously discussed, brake assembly 10 may provide a single sensor unit 30 or multiple sensor units 30. When multiple sensor units 30 are provided, the sensor units 30 may be disconnected from or connected to each other. For example, when a disconnected configuration is provided, multiple sensor units 30 may be provided on the same brake pad assembly 24 or different brake pad assemblies 24 without being physically connected at or near brake assembly 10. Multiple sensor units 30 may be provided on the same brake pad assembly 24 or different brake pad assemblies 24 and may be physically connected to each other at or near brake assembly 10 in a connected configuration. Examples of connected sensor units 30 will be discussed below primarily in the context of a configuration with two sensor units 30, where one sensor unit 30 straddles or is mounted to a first brake pad assembly 24, and another sensor unit 30 straddles or is mounted to a second brake pad assembly 24. It is contemplated that when multiple sensor units 30 are provided, the sensor units may have a different number of sensors. For example, when multiple sensor units 30 are provided, some, but not all, of the sensor units may provide a second sensor 108.

[0046] refer to Figure 1 to Figure 4 The diagram illustrates a configuration in which a first sensor unit 30 is disposed on a first brake pad assembly 24, and a second sensor unit 30 is disposed on a second brake pad assembly 24. The first and second sensor units 30 are depicted aligned with each other and positioned directly opposite each other; however, it is contemplated that the first and second sensor units 30 could be arranged in other positions. Figure 3As best shown, the connection member 170 can extend from the first sensor unit 30 to the second sensor unit 30. In at least one configuration, the connection member 170 can extend from the front body 100 of the first sensor unit 30 to the front body 100 of the second sensor unit 30. The connection member 170 can be configured as a pliable or bendable member that can allow the first sensor unit 30 and the second sensor unit 30 to move toward one another upon application of the brake (e.g., when the first brake pad assembly 24 and the second brake pad assembly 24 are actuated toward the brake rotor 40) and can allow the first sensor unit 30 and the second sensor unit 30 to move away from one another upon release of the brake (e.g., when the first brake pad assembly 24 and the second brake pad assembly 24 move away from the brake rotor 40). As such, the shape or orientation of the connection member 170 can change during operation of the brake assembly 10. Additionally, the connection member 170 can be provided with sufficient length to accommodate brake application and brake release regardless of the amount of wear of the friction material 82 (i.e., the connection member 170 can accommodate both unworn and fully worn brake pad assemblies). The connection member 170 can be integrally formed with the first sensor unit 30, the second sensor unit 30, or both. For example, the connection member 170 can be molded with the first sensor unit 30 and the second sensor unit 30 to provide a unitary component.

[0047] Referring to Figure 7 The connection member 170 can receive one or more connection electrical conductors 110 that can extend between the first sensor unit 30 and the second sensor unit 30. Such a connection member 170 can be provided in various configurations. For example, the connection member 170 can be configured as a hollow tube through which the one or more connection electrical conductors 110 can extend. Alternatively or additionally, the connection member 170 can be molded or formed around the one or more connection electrical conductors 110 such that the connection member 170 contacts and encapsulates the connection electrical conductors 110.

[0048] Referring to Figure 8One or more connecting electrical conductors 110 extending between the first sensor unit 30 and the second sensor unit 30 can be disposed externally to the connecting member 170. For example, the one or more connecting electrical conductors 110 can loop or spiral around the connecting member 170, or can be attached to the connecting member 170. As such, the connecting member 170 can help support the connecting electrical conductors 110 in a manner that can help prevent crushing or excessive bending of the connecting electrical conductors 110 that can cause the connecting electrical conductors 110 to break or be damaged. In such a configuration, the connecting member 170 can be solid or hollow. Further, the connecting member 170 can flex during a braking operation, or can be configured to maintain its shape. If the connecting member 170 maintains its shape, the sensor units 30 can slide along the connecting member 170 during brake application and release. For example, the connecting member 170 can extend through a hole in the sensor units 30, and can have a length that does not interfere with brake application or release.

[0049] Referring to Figure 9 and Figure 10 , a configuration is shown in which the connecting member 170' can be mountable to the brake pad retraction springs 32. As best shown in Figure 9 , the brake assembly 10 can provide one or more brake pad retraction springs 32. The brake pad retraction springs 32 can facilitate retraction of the brake pad assemblies 24 away from the brake rotor 40 when no braking force is applied. As such, the brake pad retraction springs 32 can bias the brake pad assemblies 24 away from the brake rotor 40 and away from each other. In Figure 9 , first and second brake pad retraction springs 32 are shown that can extend in opposite lateral directions from the retainer band 26, or to the left and right from the angle shown in Figure 9 . The brake pad retraction springs 32 can extend between the first brake pad assembly 24 and the second brake pad assembly 24. For example, the brake pad retraction springs 32 can extend from the back plate 80 of the first brake pad assembly 24 to the back plate 80 of the second brake pad assembly 24. It will be understood that a brake assembly having any configuration associated with Figure 1 to Figure 8 can provide one or more brake pad retraction springs 32.

[0050] The brake pad retraction springs 32 can be provided in various configurations. As an example, the brake pad retraction springs 32 can include a first end 180, a second end 182, a coil 184, a first arm 186, and a second arm 188.

[0051] The first end 180 can be mountable to the brake pad assembly 24. For example, the first end 180 of the brake pad retraction spring 32 can be inserted into and can be received by the aperture 94 of the back plate 80 of the brake pad assembly 24.

[0052] The second end 182 can be disposed opposite the first end 180. The second end 182 can be mountable to another brake pad assembly 24. For example, the second end 182 of the brake pad retraction spring 32 can be inserted into and can be received by the aperture 94 of the back plate 80 of the brake pad assembly 24.

[0053] The coil 184 can be disposed between the first end 180 and the second end 182. The coil 184 can engage the retainer strap 26. For example, the coil 184 can contact a side of the retainer strap 26 that can face the brake rotor 40 and the cavity 70 to inhibit movement of the coil 184 away from the brake rotor 40 or rotation of the brake pad retraction spring 32 away from the brake rotor 40. The coil 184 can define a coil aperture 190 that can extend about and can encircle a coil axis. The coil aperture 190 and the coil axis can be constituted by one or more turns or helical windings of the coil 184. Such turns or helical windings can be stacked or arranged relative to one another along the coil axis.

[0054] The first arm 186 can extend from the coil 184 toward the first end 180.

[0055] The second arm 188 can be spaced apart from the first arm 186. The second arm 188 can extend from the coil 184 toward the second end 182.

[0056] With reference to Figure 9 and Figure 10 The connection member 170' can be mountable to the brake pad retraction spring 32. For example, the connection member 170' can be mountable to the coil 184. The electrical conductor 110 can be disposed inside the connection member 170', or can be encapsulated by the connection member in any of the manners previously discussed. In at least one configuration, the connection member 170' can include a flange 200 and a coil engagement feature 202, which are best shown in Figure 10 .

[0057] Flange 200 may extend from and be integrally formed with connecting member 170'. In the illustrated configuration, flange 200 is positioned closest to the center of connecting member 170' and is depicted as extending laterally from connecting member 170'. In at least one configuration, flange 200 may enclose or encapsulate reinforcing members, such as wire mesh, plates, rods, etc., to increase the rigidity of flange 200 and / or coil engagement feature 202, which in turn may help transmit forces during installation to help reduce installation work.

[0058] Coil engagement feature 202 may extend from flange 200. Coil engagement feature 202 may be mountable to or coupled to brake pad return spring 32 and / or coupled between coil 184 and retainer band 26. For example, coil engagement feature 202 may extend through coil 184 of brake pad return spring 32 to secure connecting member 170' to brake pad return spring 32. In at least one configuration, coil 184 may be secured between flange 200 and enlarged head 204 of coil engagement feature 202. Enlarged head 204 may have a diameter larger than the inner diameter of coil 184. Additionally, enlarged head 204 may have a pointed or tapered configuration that may facilitate positioning or centering of coil engagement feature 202 relative to coil hole 190 and facilitate insertion of enlarged head 204 into coil hole 190.

[0059] The coil engagement feature 202 can be inserted into the coil hole 190 from either the top or bottom side of the coil 184. Figure 9 In the configuration shown, the coil engagement feature 202 is shown to be insertable from the top side of the coil 184, such that the flange 200 can extend above the coil 184, and a portion of the flange 200 can extend between the coil 184 and the retainer band 26. Thus, a path can be planned above the brake pad return spring 32 such that the brake pad return spring 32 can support the connecting member 170' and help prevent the connecting member 170' from contacting the brake rotor 40 or being compressed between the brake pad assembly 24 and the brake rotor 40.

[0060] It is also envisioned that the connecting member 170' can be supported by or attached to the retainer band 26, such as via a clip, tray, etc. It is also envisioned that the electrical conductor 110 can be routed around the cavity 70 of the brake caliper 22 rather than across the cavity 70 of the brake caliper 22. In such a configuration, the electrical conductor 110 can be guided by one or more ribs mounted to or formed with the brake caliper 22.

[0061] refer to Figure 11FIG. 18, for example, shows an example of a configuration in which at least one sensor unit can be movable relative to the connecting member. One sensor unit 30, such as a sensor unit mounted to the outboard brake pad assembly 24, can be stationary and can be coupled to the connecting member 170". Such coupling can be accomplished in any suitable manner, such as by providing a hole, such as a blind hole, in the sensor unit 30 that receives an end of the connecting member 170". The other sensor unit 30" can be movable or slidable relative to the connecting member 170". As an example, the sensor unit 30" can have a hole into which or through which the connecting member 170" can extend. An end of the connecting member 170" disposed closest to the sensor unit 30" can be spaced apart from components such as the caliper housing 50, a cover plate of the caliper housing 50, and the abutment 60 to accommodate movement of the brake pad assembly 24. The connecting member 170" can be solid or hollow and can be non-flexible or substantially rigid.

[0062] It is contemplated that one sensor unit can be movable, or both sensor units can be movable. In Figure 11 the movement of the sensor unit 30" is shown in dashed lines. For example, the sensor unit 30" can move with the inboard brake pad assembly 24 toward the brake rotor 40 when the abutment 60 is extended, and thus slide along the connecting member 170" toward the brake rotor 40. The other sensor unit 30 can also move with the outboard brake pad assembly 24 to engage the brake rotor in response to the reaction force as previously described. It is noted that, for clarity, Figure 11 The internal components of the sensor units are not shown.

[0063] The brake assembly as described above can allow the sensor units to be mounted to the brake pad assembly without providing slots in the back plate of the brake pad assembly through which the sensor units extend, which can reduce associated costs and allow the sensor units to be compatible with back plates that lack such slots. Additionally, the back plate, friction material, and pad spring can cooperate to limit movement of the sensor units in multiple directions, which can help to better retain the sensor assembly during braking. The sensor units can package the sensors and wiring in an area that is near the friction material to help better withstand temperature and environmental conditions. A coil member can be provided inside at least a portion of the sensor unit to help improve durability of the sensor unit, protect the electrical conductors from abrasion, and help control positioning of the electrical conductors to avoid damage. Furthermore, the coil member can also act as a heat conductor, which can help to transfer some heat energy closer to the temperature sensor to facilitate temperature detection.

[0064] While the foregoing describes exemplary embodiments, these embodiments are not intended to describe all possible forms of the application. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the application. Additionally, the features of various implementing embodiments can be combined to form further embodiments of the application.

Claims

1. A brake assembly, comprising: A first brake pad assembly, the first brake pad assembly including a first friction material disposed on the front side of a first back plate; The first bushing spring is mounted on the first back plate; A first sensor unit, which straddles the first back plate and extends from the first back plate to the first bushing spring; The second brake pad assembly includes a second friction material disposed on a second back plate; The second bushing spring is mounted to the second back plate; A second sensor unit, which straddles the second back plate and extends from the second back plate to the second bushing spring; as well as A connecting conductor is provided that electrically connects the first sensor unit to the second sensor unit.

2. The brake assembly according to claim 1, wherein, The first friction material defines a recess opposite to the extension of the first bushing spring, and the first sensor unit is at least partially received in the recess.

3. The brake assembly according to claim 1, wherein, The first sensor unit includes a front body that engages the front side of the first back plate, a rear body that engages the rear side of the first back plate and is configured to be opposite the front side, and a bridge-shaped member extending from the front body to the rear body, wherein the bridge-shaped member engages the first back plate and the first bushing spring.

4. The brake assembly according to claim 3, wherein, The first friction material defines a recess that extends away from the first bushing spring, and the front body extends into the recess.

5. The brake assembly according to claim 3, wherein, Compared to the rear body extending from the first bushing spring, the front body extends further away from the first bushing spring.

6. The brake assembly according to claim 3, wherein, The front body has a front body protrusion extending away from the first friction material, the rear body has a rear body protrusion, and the first bushing spring is received between the front body protrusion and the rear body protrusion.

7. The brake assembly according to claim 3, wherein, The first sensor is encapsulated in the front body.

8. The brake assembly according to claim 7, wherein, The first sensor provides a signal indicating the wear of the first friction material.

9. The brake assembly according to claim 7, wherein, The second sensor is encapsulated within the first sensor unit behind the front body.

10. The brake assembly according to claim 9, wherein, The second sensor provides a signal indicating the temperature of the first brake pad assembly.

11. The brake assembly according to claim 9, wherein, The second sensor is encapsulated in the rear body.

12. The brake assembly according to claim 3, wherein, The sleeve extends from the first sensor unit and surrounds the electrical conductor that extends to the first sensor.

13. The brake assembly of claim 12, wherein, The sleeve includes a plurality of protrusions extending away from the electrical conductor.

14. The brake assembly of claim 13, wherein, The plurality of protrusions are spaced apart from each other and surround the electrical conductor.

15. The brake assembly of claim 12, further comprising a coil member received within the first sensor unit and the sleeve, wherein, The coil of the coil component extends around the electrical conductor.

16. The brake assembly according to claim 1, wherein, The connecting member extends from the front body of the first sensor unit to the front body of the second sensor unit.

17. The brake assembly of claim 16, wherein, The first sensor unit is movably mounted on the connecting member.

18. The brake assembly according to claim 1, wherein, The connecting member extends from the first sensor unit to the second sensor unit, and the second sensor unit and the connecting member are integrally formed.

19. The brake assembly of claim 18, wherein, A brake pad retraction spring extends from a first back plate of the first brake pad assembly to a second back plate of the second brake pad assembly and offsets the first brake pad assembly and the second brake pad assembly away from each other. The brake pad retraction spring includes a coil, and the connecting member includes a flange and a coil engagement feature that extends from the flange and through the coil to secure the coil between the flange and the coil engagement feature.

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